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More to XploR ™

XploR_42
Date: 20.10.21
Seals used in Oil & Gas applications must survive blistering heat and intense pressures as oilfields move into deeper waters. Eric Bucci, Global  Technical Manager, Energy and Oil & Gas for Trelleborg Sealing Solutions explains more about the engineering behind two products designed to withstand these conditions: XploR™ S Seal and XploR™ FS Seal. - By Jan Sklucki

IN SHORT

  1. As the oil & gas market rebounds faster than expected, increasingly challenging conditions are explored for resources.

  2. Trelleborg Sealing Solutions introduces two new seals for high pressures and temperatures: XploR™ S Seal and XploR™ FS Seal.

  3. These seals feature integrated anti-extrusion springs to provide rigidity while remaining flexible, improving performance and making installation quick and easy.

DESPITE THE SLOW-DOWN

of the global economy in 2020, the oil & gas market is rebounding faster than expected and should continue to grow over the following years as economies further re-open.1 Growth in the industry is expected to be dominated by demand for natural gas rather than oil.

Gas production has recovered quickly despite COVID-19, accelerated by environmental concerns around coal and oil. As reserves in increasingly harsh conditions are tapped, pressure and temperature requirements for seals increase. To extract these resources effectively, reliably, and safely, Trelleborg Sealing Solutions has expanded its portfolio for today’s oil & gas applications with two new products.

XploR_FS_Seal
Secret to strength

The XploR™ S Seal and XploR™ FS Seal are both primary, bidirectional, static seals optimized for stability in the groove under high pressures and temperatures. They each have specially designed profiles and can be custom engineered to adapt them to different applications, from downhole tools to wellheads and tubing hangers. 


The secret behind their strength is the two integrated anti-extrusion springs, which provide a rigid backbone while maintaining flexibility. Hidden beneath the rubber, they provide strong extrusion resistance to the seal while the elastomer element maintains a gas-tight seal when un-pressurized.  During operation, the springs work with the pressure to increase the sealing effect. “As system pressure increases, the anti-extrusion springs are forced into the extrusion gap area providing a robust and reliable seal. Coupled with the rubber sealing interface, leak-free operation is possible and allows for significantly reduced emissions,” says Eric.

Consolidating components

One of the key reasons to select the XploR™ S Seal or XploR™ FS Seal is to consolidate several seals into one. Applications such as downhole tools can require a complex arrangement of seals, including supporting components like anti-extrusion rings to keep running effectively. As well as requiring more space within the assembly and additional installation grooves, each extra seal costs more time for an engineer to install. “The XploR™ S Seal and XploR™ FS Seal are an effective one-piece replacement for arrangements involving O-Rings, Back-up Rings, U-Cups, and T-Seals,” says Eric. “And though the springs are strong and rigid enough to provide the necessary anti-extrusion support to the elastomer, they remain flexible enough to allow easy installation into solid grooves, saving more time.”

 

Outside of installation, reducing the number of seals means that ordering can be streamlined, simplifying procurement, and reducing the part numbers to manage. Though a range of parts to standard O-Ring groove sizes is available to select from quickly and easily, Trelleborg Sealing Solutions is also interested in supporting non-standard and novel applications with customized products tailored specifically to that use. “We have worked with customers from an early design stage to provide custom-designed seals for specialized projects and have shipped many already that are working well within the application,” says Eric. When applicable, each custom seal is evaluated by engineering teams and simulated using FEA to verify form, fit, and function.

Materials and testing
Materials and testing

The operating parameters of the seal are mainly decided by the material choice. The XploR™ range is renowned within the Oil & Gas industry and is specified as standard for both products. Resistant to Rapid Gas Decompression (RGD) and aggressive process media, the materials conform to necessary approvals and standards, such as ISO 23936-2 (NORSOK M-710), API-16C, and ISO 10423. 

 

“Compounds behave differently under different conditions, and often to increase performance in one area, another property, such as media compatibility or temperature range, must be compromised on. It takes knowledge and skill to balance these factors and create a material that perfectly fits an application. That’s what we’ve done with the XploR™ materials; matching the compound with the application,” says Eric.

 

The XploR® range is drawn from a larger portfolio of materials, including the high-specification Isolast® compounds, which are available for use when required.


To provide confidence in the performance of the design and materials, Trelleborg Sealing Solutions undertook testing regimes relevant to oil & gas regulations. The products are validated in accordance with ISO 10423 Annex F conditions at a range of key temperatures. “The validation testing is very difficult, yet Trelleborg Sealing Solutions has one of the largest compliant material portfolios in the industry,” says Eric.

Hardware-friendly

“As with the seal material, what the spring is made of should also be adapted based on the conditions that the seal experiences,” continues Eric. Under lower pressure working conditions, a stainless-steel garter spring provides the resilience required without hardware damage. However, in high pressure and temperature applications, such as downhole tools, small movements of the seal or housing in reaction to pressure or temperature can cause wear on mating surfaces.


To minimize any possible damage, a composite spring material can be substituted for the metal. “We might call this the ’hardware-friendly’ version, and few other companies offer it as an option,” says Eric. “Carbon fiber springs eliminate the risk of damage to the housing without compromising on strength or elevated temperature performance,”


The seals join an already impressive selections of products for the Oil & Gas market. “The XploR™ S Seal and XploR™ FS Seal are another step in enhancing the Trelleborg Sealing Solutions Oil & Gas elastomer portfolio and confirming our reputation as a one-stop-shop,” finishes Eric.

Xplor-F_FS_Seal
XPLOR™ S SEAL AND XPLOR™ FS SEAL

Primary one-piece static seals for Oil & Gas applications. They give bubble-tight sealing at high pressures and temperatures with superior extrusion resistance. Their design manages high hardware tolerances and applications, such as valves and downhole tools where pressure can cause ballooning of hardware.


FEATURES 

  •  High pressures up to 103.4 MPa / 15000 psi
  • Temperatures up to -45 °C / +260 °C ; -49 °F / +500 °F depending on material choice
  • Replace several components with a single seal
  • Compliant with multiple industry standards, such as ISO 29001 Oil & Gas design & manufacturing.
  • Compliance to API 6A / ISO, API-16C 10423 Annex F, PSL 3 & 4; Materials compliant to NORSOK M710.
  • Material choices to meet any conditions
  • Cost-effective
  • Robust and flexible with symmetrical cross-section for error-free installation
  • Seals effective even with relatively rough surfaces
  • Same quality and standard product anywhere in the world

APPLICATIONS: Oil & Gas industry, including Drilling Tools, Downhole Tools, Trees, Wellheads, Valves, Risers & Connectors, Coil Tubing Equipment, and Fracking Equipment. Chemical Processing and Transport.